Apparatus for arranging fibers in grid form



April 23, 1968 sTUTZ APPARATUS FOR ARRANGING FIBERS IN GRID FORM Filed June 15, 1964 FIG. I;

INVENTOR. F RA N K S TU TZ United States Patent O ABSTRACT OF THE DISCLOSURE An apparatus for producing nonwoven grid-shaped fab rics comprising a rotatable propelling ring having fiber grips mounted thereon which act to lay weft fibers on warp fibers as the warp fibers pass through the propelling ring.

Heretofore, fabrics were manufactured by weaving, knitting or by some process of producing nonwovens such as felt. Each of the aforementioned fabrics have advantages which the others do not possess; however, this invention discloses an apparatus which is not woven but has all of the characteristics thereof. This novel fabric has its fibers laid out in grid form with the fibers being bound together at their points of contact thereby giving the fabric good tensile strength with porosity, air-permeability, flexibility, softness and the appearance and hand of a woven fabric. It is also expected that this particular arrangement will considerably reduce creep and permanent set of fabric when under tension load and that the production rate will be at least as great as or greater than many modern ways knitting machines. This fabric resembles woven fabrics in as much as it consists of two systems of substantially straight threads, the systems being parallel and the fibers of the systems being perpendicular.

The prior art discloses many apparatuses for the poduction of nonwoven fabrics but nowhere does the art teach the particular relationship as herein disclosed. The prior art teaches the irregular arrangement of fibers in overlapping engagement but there has not been a disclosure of an apparatus for arranging the weft fibers perpendicularly to the warp fibers. It is submitted that this invention substantially contributes to the art.

Therefore, an object of this invention is to provide an apparatus for the production of nonwoven fabric having .the characteristics of woven fabric.

Another object of this invention is to provide an ap par-atus for laying weft fibers perpendicularly on warp fibers and bonding the two systems of fibers together at their points of contact.

A further object of this invention is to provide an apparatus for continuously superposing weft fibers perpendicularly on warp fibers by using a ring member which acts as a shuttle.

Other objects and advantages of this invention will become apparent when the following detailed description is read in conjunction with the appended drawings, specifications and claims. Preferred embodiments of this invention will now be described with reference to the accompanying drawings wherein:

FIGURE 1 is a front view of the apparatus showing the first fiber grip grasping the weft fiber and the second fiber grip having released the weft fiber;

FIGURE 2 is a front view of the apparatus showing the first fiber grip bringing the weft fiber across the surface of the fabric;

FIGURE 3 is a front view of the apparatus showing the first fiber grip advancing the weft fiber and the second fiber grip coming into position to grip said fiber.

FIGURE 4 is a perspective view of the apparatus show- 3,379,596 Patented Apr. 23, 1968 ing the cooperation among the various elements of the apparatus; and

FIGURE 5 is an end view of another embodiment of the apparatus wherein the Weft yarn is fed in from two sides to the fiber grips.

FIGURE 6 is a perspective view showing the structure of fiber grips contemplated in this invention.

One embodiment of the present invention contemplates the production of a continuous bonded scrim. This machine has no reciprocating parts and, therefore, has a very high rate of production. At very high speeds, reciprocating parts such as a shuttle have high inertial forces and the machine has to be designed so as to be able to produce and contain these forces. Since the textile yarn usually have a small mass, inertial force will be no problem as long as the yarn is executing a reciprocating move ment. The apparatus described below produces a bonded scrim by rotating all of the movable parts.

In operation, the warp fibers are continuously moved over a table. A propelling ring which rotates around its radial axis is placed around the table for carrying the warp fibers. It is supported and driven by three or more rolls which are spaced therearound having surfaces contiguous with the outer surface of the propelling rings. The propelling ring has mounted thereon at least two fiber grips having knives or cutting surfaces associated there with. The fiber grip grasps the weft fiber and cuts it away from the fabric in the same motion, after which it carries the fiber around'and lays it on the fabric. Meanwhile, a second fiber grip, being diametrically and oppositely mounted on the propelling ring, releases the weft fiber at approximately the same time the first fiber grip grasps. The two fiber grips function exactly alike.

For higher production rates, more propelling rings may be used. Also, the weft fibers may be fed into the apparatus from both sides. If such is the case, the table does not extend to the point of contact between the weft fibers and the warp fibers for the weft fiber is laid on the warp fibers on both sides.

The fibers are bonded together at the points of contact by a solvent or an adhesive, the particulars of which will be discussed below.

The invention is illustrated with the accompanying drawings in which the figures are illustrative of the preferred embodiment of the invention.

Warp fibers 10 are fed to the apparatus on a table 11 from a source (not shown). Weft fibers 12 are fed to the apparatus from a cone 13. Both the warp fibers and the weft fiber have been coated by an adhesive or a solvent which are contained in warp fiber bath 14 and weft fiber bath 15. Whereas some adhesives may be effectively used, it has been found that a solvent is more suitable for this invention for the problems of handling glue are eliminated. One excellent solvent for acrylonitrile-based fibers is ethylene carbonate. When ethylene carbonate is applied to a fiber, the outer layer begins to dissolve and upon joining a plurality of such coated fibers, molecular chains which comprise the fibers intertwine and become permanently set by evaporating the ethylene carbonate. The ethylene carbonate in no way adversely affects the characteristics of the fibers for the fibers are essentially welded together at the points of contact. Other solvents may be used, namely, zinc fiuoroborate; however, this solvent and most others leave undesirable characteristics; such as, a tacky surface or the like. For nylon, formic acid or any of the Hoffmeister series of compounds are good solvents. Where cotton or wool is used, an adhesive especially one having a latex base may be used to bond the touching fibers together. In general, any adhesive or solvent may be used which does not interfere with the utility of the resulting fabric.

After coating warp fibers and weft fiber 12 with a solvent, weft fiber 12 is laid on warp fibers 10 after the outer surfaces of the fibers have been partially dissolved by the solvent. By joining the fibers in such a manner, the molecules of each intermix and upon the evaporation of the ethylene carbonate, the fibers become fused together at the points of intersection. The solvent may be evaporated by blOwing a stream of hot air on the fabric (not shown) or it may be evaporated by running the fabric through an evaporator 50. Evaporator 50 is heated by any well known means such as, electric coils, steam coils or the like.

To lay the weft fiber 12 thereon, the apparatus is provided with a propelling ring 16 which is held in pOsitiOn and rotated by positive driven rolls 17, 18 and 19 which are mounted on shafts 20, 21, and 22, respectively. All of the rolls do not have to be positively driven, one would be sufiicient; however, there must be at least three rolls to support propelling ring 16. At least two fiber grips is mounted on propelling ring 16. Fiber grip 25, as shown in FIGURE 6, functions like a pair of scissors in that it is comprised of two blades joined by a shaft in a manner to let one blade open and close against the other blade. Blade 26 is rigidly connected to propelling ring 16 by stake 27. Pivoting about shaft 28 which is rigidly mounted on blade 26 is a holding blade 29. Holding blade 29 has a roller 30 mounted on one end and a small plate 31 mounted on the other. Roller 30 is pulled against the side of propelling ring 16 by a spring 32 which is mounted under tension between blade 26 and holding blade 29. Holding blade 29 pivots outwardly from blade 26 when roller 30 travels over a cam 33. Cam 33 is designed to actuate holding blade 29 in a manner which allows the plate end thereof to move from a position of conact with the corresponding end of plate 26 to a position away therefrom in order to receive and hold a fiber. The free end of blade 26 has a guide post 34 which extends upwardly from and makes an acute angle with blade 26. As the blades pass under weft fiber 12, guide post 34 catches and guides weft fiber 12 into the angle whereupon roller 30 falls back to its normal position which is against propelling ring 16 thereby impinging weft fiber 12 against blade 26 by plate 31 and holding the same there. When the blades engage the weft fiber 12, a knife 35 which is mounted on table 11 and extends to a position adjacent to propelling ring 16 cuts weft fiber 12 whereupon the blades having the weft fiber 12 clutched therein travels on propelling ring 16 to a position diametrically opposite the position of receiving weft fiber 12. Referring to FIGURE 4, as one of the fiber grips carries a weft fiber over and lays it upon the warp fibers, the weft fiber can ride over a dull upper surface and under a sharp lower surface of knife 35 whereupon it is caught by the opposite fiber grip. The weft fiber will be cut as this opposite fiber grip proceeds to lay a weft fiber on the warp fibers. At this position, a cam 38 forces holding blade 29 outwardly thereby releasing weft fiber 12. This process is repeated in the same manner to form a nonwoven fabric, the fibers of which are aligned in grid form. As shown, two pairs of scissors are employed; however, it is obvious that more in mutlitples of two may be used where it is convenient to do so.

As shown in FIGURE 5, a second yarn supply 40 may be used. The process of the same as outlined above, the only dififerences being that the resulting fabric has weft fibers bonded to both sides of the warp fibers.

Many diiferent embodiments of this invention may be made without departing from the scope and spirit thereof. It is to be understood that this invention is not to be limited to the specific embodiments shown and de scribed herein, except as defined in the appended claims.

I claim:

1. An apparatus for aligning continuous fibers in grid form for producing a fabric comprising:

(a) a table, said table being adapted to receive warp fibers from a source,

=(b) an applicator bath in juxtaposition with said table for receiving and wetting said warp fibers with a bonding agent,

(0) a propelling ring rotatably mounted around said table, said propelling ring having thereon at least two fiber grips having blades cooperating to open and close on a weft fiber,

(d) means for applying a bonding agent to said weft fiber.

2. An apparatus for aligning continuous fibers in grid form for producing a fabric comprising:

(a) a table, said table being adapted to receive warp fibers from a source,

(b) an applicator bath in juxtaposition with said table for receiving and wetting said warp fibers with a bonding agent,

(c) a plurality of rolls at least one of which being positively driven spamd about said table,

(d) a propelling ring mounted for rotation by said rolls and mounted around said table,

(e) at least two fiber grips mounted on said ring, said fiber grips having blades cooperating to open and close on a Weft fiber and being adapted to receive and place a weft fiber on said warp fibers,

(f) an applicator bath in juxtaposition with said table for wetting said weft fiber with a bonding agent, and

(g) an evaporator positioned to receive and disperse said fabric.

3. An apparatus for aligning continuous fibers in grid form for producing a fabric comprising:

(a) a table, said table being adaped to receive and align warp fibers,

(b) an applicator bath in juxtaposition with said table for receiving and wetting said warp fibers with a bonding agent,

(c) a plurality of rolls at least one of which being positively driven spaced about said table,

(d) a propelling ring being received and rotated by said rolls, said propelling ring extending around said table,

(e) at least two fiber grips mounted on said propelling ring, said fiber grips having blades cooperating to open and close on a weft fiber,

(f) a cam positioned adjacent to and on the inside of said propelling ring, said cam being adapted to open said fiber grips,

(g) an applicator bath in juxtaposition with said table for wetting said weft fiber with a bonding agent, and

(h) an evaporator positioned to receive and disperse said fabric.

4. An apparatus for producing a nonwoven fabric comprised of fibers arranged in grid form comprising:

(a) a table, said table being adapted to receive and align warp fibers,

(b) an applicator bath in juxtaposition with said table for receiving and wetting said warp fibers with a bonding agent,

(c) a plurality of rolls, at least one of which is driveable, spaced about said table,

(d) a propelling ring received and rotatable by said rolls, said propelling ring extending around said table,

(e) at least two fiber grips mounted on said propelling ring, said fiber grips having blades cooperating to open and close on a weft fiber,

(f) a cam positioned adjacent to and on the inside of said propelling ring, said cam being adapted to open said fiber grips,

(g) a knife secured to said table, said knife cooperating with said fiber grips and said propelling ring to cut said weft fiber,

-'(h) an applicator bath in juxtaposition with said table for wetting said weft with a bonding agent, and

5 6 (i) an evaporator positioned to receive and disperse 3,041,230 6/ 1962 Diehl 156-439 X said fabric. 3,271,219 6/1966 Nickerson, et a1. 156-440 X 3,275,489 9/1966 Talv 156-440 References Cited UNITED STATES PATENTS 5 EARL M. BERGERT, Primary Examiner. 1 353 5 2 1921 Wands} 15 439 J. P. MELOCHE, D. J. FRITSCH, Assistant Examiners. 

